System for manufacturing string of pocketed coil springs

ABSTRACT

A system for manufacturing a string of pocketed coil springs comprising: a coil-forming subsystem that produces two coil springs; a spring transporter subsystem that receives the two coil springs at a first position and conveys the two coil springs to a second position; a spring compressor subsystem that compresses the two coil springs; a fabric-folding subsystem that receives a piece of fabric and folds the fabric to create an open side; a spring inserter subsystem that receives the two compressed coil springs and inserts the two compressed coil springs between top and bottom surfaces of a folded piece of fabric; two welder subsystems that form first and second welds between top and bottom surfaces of the folded piece of fabric, the first welds and the second welds forming a plurality of pockets in the fabric, each of the plurality of pockets comprising a compressed coil spring.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit under 35 U.S.C. § 119(e) of U.S.Provisional Patent Application No. 62/089,610, filed 9 Dec. 2014,entitled “Multi-Head Spring Coilers and Methods of Using Same,” which isincorporated herein by references as if set forth herein in itsentirety.

TECHNICAL FIELD OF THE INVENTION

The various embodiments of the present disclosure relate generally tocoilers. More particularly, the various embodiments of the presentinvention are directed to systems and methods for manufacturing stringsof pocketed coils to be used to assemble a mattress.

BACKGROUND OF THE INVENTION

Spring form mattresses are conventionally manufactured through theassembly of multiple strings of pocketed coils. A string of pocketedcoils comprises an elongated piece of fabric with individual pocketslocated therein, each pocket encompassing an individual spring. Parallelstring segments can be bonded together to form a mattress assembly.

The mattress assembly process typically consists of two differentstations or systems—a coiler that receives a fabric and wire to producea string of pocketed coils and an assembler that receives the string ofpocketed coils and assembles parallel segments of the string together toform the mattress assembly. Because each string segment processed by theassembler comprises multiple pocketed coils, which must first be createdby the coiler, the coiler is commonly understood to be the bottleneck ofthe manufacturing process.

Therefore, there is a desire for improved coilers capable ofmanufacturing pocketed coils in a faster and more efficient manner.Various embodiments of the present invention address such a desire.

BRIEF SUMMARY OF THE INVENTION

The present invention relates to systems and methods for manufacturing astring of pocketed coils. An exemplary embodiment of the presentinvention provides multi-head coiler comprising at least two springcoilers, a spring transporter, a spring compressor, a fabric foldingmember, a spring inserter, a first welder, a second welder, and a springexpander. Each of the at least two spring coilers can be configured tosimultaneously produce a spring coil. The spring transporter can beconfigured to simultaneously receive the at last two spring coilsproduced by the spring coilers and transport the at least two springcoils to the spring compressor. The spring compressor can be configuredto simultaneously compress the at least two spring coils. The fabricfolding member can be configured to receive an elongated piece of fabricand fold the piece of fabric along its longitudinal axis to create topand bottom fabric plies. The spring inserter can be configured tosimultaneously receive the at least two compressed spring coils andsimultaneously insert the at least two compressed spring coils betweenthe top and bottom fabric plies. The first welder can be configured toweld an edge of the folded fabric parallel to the longitudinal axis ofthe fabric and opposite the folded edge of the fabric to join the topand bottom fabric plies. The second welder can be configured to weld thetop and bottom fabric plies together along lines that are transverse tothe longitudinal axis of the fabric between each of the compressedspring coils to create a plurality of pockets in the fabric, each pocketencompassing a compressed spring coil. The spring expander can beconfigured to expand each of the compressed spring coils within theplurality of pockets.

The present invention also provides methods of making a string ofpocketed springs. In an exemplary embodiment of the present invention,the method comprises: simultaneously making at least two spring coils;simultaneously transporting the at least two spring coils to acompressor; simultaneously compressing the at least two spring coils;simultaneously inserting the at least two compressed spring coilsbetween top and bottom plies of a piece of fabric folded along itslongitudinal axis; welding the top and bottom plies of the fabric alonga long edge of the folded fabric parallel to the longitudinal axis ofthe fabric and opposite the folded edge of the fabric; welding the topand bottom plies of the fabric along lines that are transverse to thelongitudinal axis of the fabric between each of the compressed springcoils to create a plurality of pockets in the fabric, each pocketencompassing a compressed spring coil; and expanding each of thecompressed spring coils with each of the plurality of pockets.

These and other aspects of the present invention are described in theDetailed Description of the Invention below and the accompanyingfigures. Other aspects and features of embodiments of the presentinvention will become apparent to those of ordinary skill in the artupon reviewing the following description of specific, exemplaryembodiments of the present invention in concert with the figures. Whilefeatures of the present invention may be discussed relative to certainembodiments and figures, all embodiments of the present invention caninclude one or more of the features discussed herein. Further, while oneor more embodiments may be discussed as having certain advantageousfeatures, one or more of such features may also be used with the variousembodiments of the invention discussed herein. In similar fashion, whileexemplary embodiments may be discussed below as device, system, ormethod embodiments, it is to be understood that such exemplaryembodiments can be implemented in various devices, systems, and methodsof the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The following Detailed Description of the Invention is better understoodwhen read in conjunction with the appended drawings. For the purposes ofillustration, there is shown in the drawings exemplary embodiments, butthe subject matter is not limited to the specific elements andinstrumentalities disclosed.

FIG. 1 provides a perspective view of a system for producing a string ofpocketed spring coils, in accordance with an exemplary embodiment of thepresent invention.

FIG. 2 provides a perspective view of a portion of the system shown inFIG. 1 proximate the first and second coilers, in accordance with anexemplary embodiment of the present invention.

FIG. 3 provides a perspective view of a portion of the system shown inFIG. 1 proximate the first coiler, in accordance with an exemplaryembodiment of the present invention.

FIG. 4 provides a perspective view of a portion of the system shown inFIG. 1 proximate the first transport wheel and first coiler, inaccordance with an exemplary embodiment of the present invention.

FIG. 5 provides a perspective view of a portion of the system shown inFIG. 1 proximate the first and second transport wheels and the conveyor,in accordance with an exemplary embodiment of the present invention.

FIG. 6 provides a perspective view of a portion of the system shown inFIG. 1 proximate the compressor and conveyor, in accordance with anexemplary embodiment of the present invention.

FIG. 7 provides a perspective view of a system for producing a string ofpocketed spring coils, in accordance with an exemplary embodiment of thepresent invention.

FIG. 8 provides a perspective view of a portion of the system shown inFIG. 1 proximate the compressor and conveyor, in accordance with anexemplary embodiment of the present invention.

FIG. 9a provides a perspective view of a portion of the system shown inFIG. 1 proximate the conveyor and spring inserter, in accordance with anexemplary embodiment of the present invention. FIG. 9b provides a viewof a push plate, in accordance with an exemplary embodiment of thepresent invention.

FIG. 10 provides a perspective view of a system for producing a stringof pocketed spring coils, in accordance with an exemplary embodiment ofthe present invention.

FIG. 11a provides a perspective view of a portion of the system shown inFIG. 1 proximate the spring inserter, conveyor, first welder, and secondwelder, in accordance with an exemplary embodiment of the presentinvention. FIG. 11b provides a view of a conveyor system fortransporting the fabric, in accordance with an exemplary embodiment ofthe present invention.

FIG. 12 provides a perspective view of a portion of the system shown inFIG. 1 proximate the spring inserter, conveyor, first welder, and secondwelder, in accordance with an exemplary embodiment of the presentinvention.

FIG. 13 provides a perspective view of a portion of the system shown inFIG. 1 proximate the first coiler and first transport wheel, inaccordance with an exemplary embodiment of the present invention.

FIG. 14 provides a perspective view of a portion of the system shown inFIG. 1 proximate the spring inserter and conveyor, in accordance with anexemplary embodiment of the present invention.

FIG. 15 provides a perspective view of a portion of the system shown inFIG. 1 proximate the spring inserter and conveyor, in accordance with anexemplary embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

To facilitate an understanding of the principles and features of thepresent invention, various illustrative embodiments are explained below.The components, steps, and materials described hereinafter as making upvarious elements of the invention are intended to be illustrative andnot restrictive. Many suitable components, steps, and materials thatwould perform the same or similar functions as the components, steps,and materials described herein are intended to be embraced within thescope of the invention. Such other components, steps, and materials notdescribed herein can include, but are not limited to, similar componentsor steps that are developed after development of the invention.

As discussed above, the bottleneck of the conventional mattress assemblysystems is in the system for producing the string of pocketed springcoils. Specifically, conventional systems are unable to produce thestring of coils at a rate that can keep up with the speed at which theassembler can assemble segments of the string of coils. One reason forthis drawback is that conventional systems only operate on a singlespring coil at any given time while the coil traverses the differentstations of conventional systems.

The present invention addresses these disadvantages of conventionalsystems by providing systems that produce a string of pocketed coilsmuch faster and more efficient than conventional systems. One way inwhich this is accomplished in the present invention is through thesimultaneous processing of multiple spring coils through the inventivesystems. As shown in FIGS. 1-15, an exemplary embodiment of the presentinvention is shown in which two spring coils are processedsimultaneously at various portions of the system. The dual-coil systemshown is shown in the associated figures and discussed below forpurposes of simplification only. The present invention, however, is notlimited to systems that process two spring coils simultaneously. Rather,those skilled in the art would recognize that the present inventionencompasses systems capable of processing more than two spring coilssimultaneously, including, but not limited to, systems for processing 3,4, 5, or 6 coils simultaneously.

Embodiments of the present invention can comprise at least two springcoilers configured to produce spring coils. The number of spring coilerscan vary in accordance with various embodiments of the presentinvention. For convenience, an embodiment with two spring coilers 105106 is discussed below. As shown in FIGS. 1-2, an exemplary embodimentof the present invention comprises a first spring coiler and a secondspring coiler. Each coiler 105 106 can operated independently of theother to produce spring coils. The first and second coiler 105 106 canoperate to produce spring coils simultaneously. For convenience,operation of the first coiler 105 is described below. Unless specifiedotherwise, operation of the second coiler 106 is substantially similarto the first coiler 105.

The first coiler 105 is configured to receive a wire from a wire source.The first coiler 105 can have a plurality of wire guide/feed/drivewheels 205 210 of varying shapes and sizes for guiding the wired to theappropriate position within the coiler 105. The wire can be pulled intothe coiler 105 through two opposing drive/feed wheels 210, each of whichcan be driven by a motor. As the wire enters the coiler 105 it can bedeflected by a curvature member 215 and a pitch member 220. The positionof the curvature member 215 can be adjusted to alter the desired radiusof curvature for the spring coil. In some embodiments of the presentinvention, the position of the curvature member 215 can be adjustedduring production of a spring coil to vary the radius of curvature atvarious portions of the same spring coil. For example, this could allowthe radius of curvature to be greater at the center of the spring coilthan at the ends. In an exemplary embodiment of the present invention,the curvature member 215 is rotatably connected to a body of the coiler105. As the curvature member 215 rotates, a distance of the wirecontacting surface of the curvature member 215 to the guide wheels 210and/or an angle of the wire contacting surface with respect the incomingwire can change to alter the radius of curvature. In some embodiments ofthe present invention, the curvature member 215 can move translationally(as opposed to rotatably) with respect to the wire guides 210 to varythe distance of the wire contacting surface of the curvature member 215to the guide wheels 210 and/or an angle of the wire contacting surfacewith respect the incoming wire to alter the radius of curvature. In someembodiments of the present invention, the curvature member 215 can moverotatably and translationally. In some embodiments, the curvature member215 can move only rotatably. In some embodiments, the curvature member215 can move only translationally. Movement of the curvature member 215can be accomplished through many different ways known in the art. In anexemplary embodiment, the curvature member 215 can be moved by aservomotor. For example, for rotational movement, the output shaft ofthe servomotor can be directly connected to the curvature member 215,such that rotation of the output shaft causes rotation of the curvaturemember 215. For example, for translational movement, the output shaft ofthe servomotor can be coupled to the curvature member 215 via a wormgear.

As discussed above, the first coiler 105 can also comprise a pitchmember 220 for controlling the pitch of the spring coil (i.e., thenumber of revolutions the wire makes over a certain distance along thelongitudinal axis of the spring coil). The distance from the wirecontacting surface of the pitch member 220 to the wire guide and/or theangle of the wire contacting surface with respect to the incoming wirecan be varied to control the pitch. In some embodiments of the presentinvention, the pitch member 220 is rotatably connected to the body ofthe coiler such that rotation of the pitch member 220 can vary thedistance from the wire contacting surface of the pitch member 220 to thewire guide 210 and/or the angle of the wire contacting surface withrespect to the incoming wire to control the pitch. In some embodimentsof the present invention, the pitch member 220 can move translationallywith respect to the wire guide 210 to vary the distance from the wirecontacting surface of the pitch member 220 to the wire guide 210 and/orthe angle of the wire contacting surface with respect to the incomingwire to control the pitch. Movement of the pitch member 220 can beaccomplished through many different ways known in the art. In anexemplary embodiment, the pitch member 220 can be moved by a servomotor.In an exemplary embodiment, for rotational movement, the output shaft ofthe servomotor can be directly connected to the pitch member 220, suchthat rotation of the output shaft causes rotation of the pitch member220. In another exemplary embodiment, for translational movement, theoutput shaft of the servomotor can be coupled to the pitch member 220via a worm gear.

Some embodiments of the present invention can further comprise a springcoil transporter for transporting the springs from the spring coilers105 106 to a spring compressor 525. The spring transporter can beconfigured to simultaneously receive a coil from each of the two or morespring coilers and simultaneously transport the spring coils to thespring compressor 525. As shown in FIGS. 1-5 and 7, in an exemplaryembodiment of the present invention, the spring transporter can comprisea spring transport wheel 110 111 for each of the spring coilers 105 106.The spring transport wheel 110 111 can have a plurality of recesses 113for receiving and holding the spring coils during transportation to thecompressor 525. The transport wheels 110 111can receive a spring in arecess 113 of the transport wheel 110 111 from their respective springcoiler 105 106. The transport wheel 110 111 can then rotate to advancethe spring coil to the spring compressor 525 and allow another springcoil from the spring coiler 105 106 to be received in an adjacent recess113 to the recess carrying the previous spring coil. Once the transportwheels 110 111 rotate to an output position for each wheel 110 111, thespring coil can fall out of the recess of the transport wheel 110 111 toa platform 505 for each transport wheel 110 111 where in injection arm510 of each platform 505 can push the spring coil into a basket 516 on aconveyor 115 having a plurality of baskets 515 516 517 518. Theinjection arms 510 can simultaneously inject a spring coil from eachtransport wheel 110 111 into a corresponding basket 516 of the conveyor115. The conveyor 115 can then rotate to advance the spring coilstowards the spring compressor 525.

Various embodiments of the present invention can also comprise acompressor 525 to compress the spring coils. In an exemplary embodiment,at least two springs can be simultaneously compressed. In an exemplaryembodiment, the spring compressor 525 comprises a plurality ofcompression arms 510 configured to compress the spring coils along theirlongitudinal axis. The compression arms 510 can compress the springsmany different ways known in the art, including, but not limited to,pneumatic actuation, hydraulic actuation, spring actuation, worm gears,and the like. In some embodiments, the compression arms 510 can extendinto baskets 517 518 of the conveyor to compress the spring coils. Insome embodiments, the compression arms 510 can extend into adjacentbaskets 517 518 of the conveyor.

After the springs are compressed, the compressed springs can betransported into a spring inserter 120. As shown in FIGS. 7, 9 a, and10-12, the spring inserter 120 can comprise a plurality of apertures 901for receiving the compressed springs. The spring inserter 120 can alsorotate through a plurality of positions 920 925 930 935. In oneembodiment, the spring inserter 120 comprises an input position 930 andan output position 935. In some embodiments, the spring inserter 120comprises a plurality of sides, each capable of rotating from the inputposition 930, to the output position 935, and back to the input position930. In some embodiments, each side of the spring inserter 120 comprisesan aperture 901 to receive each compressed spring. For example, as shownin FIGS. 7, 9 a, and 10-12, two springs are compressed by the springcompressor 525 in two adjacent baskets 517 518 of the conveyor 115. Oncethe springs are compressed, the springs can be inserted into adjacentapertures 901 on the same side of the spring inserter 120 at an inputposition 930. Once the compressed springs are inserted into theapertures 901 on a side of the spring inserter 120, the spring inserter120 can rotate to a second position 920 925 935, such that a second sideof the spring inserter 120 is not at the input position and ready toreceive compressed springs. Rotation of the spring inserter 120 cancontinue until the first side of the spring inserter is located at anoutput position 935. At the output position 935, the compressed springscan be ejected from the spring inserter 120 and inserted between top andbottom plies of a piece of fabric (not shown). In some embodiments, thecompressed springs can be ejected from the spring inserter 120 betweenthe top and bottom plies using a push plate 940, as shown in FIGS. 9band 15. In some embodiments, as shown in FIG. 9b , a push plate 940 cancomprise a first end 941 and a second end 942. In some embodiments, thesecond end 942 can push the compressed springs out of the apertures 901of the spring inserter 120. In some embodiments, the second end 942comprises a protruding first side 943 and an indented second side 944,which may include a half-moon shape. Accordingly, in some embodiments,when the second end 942 is inserted (i.e., plunged) through an aperture901 of the spring inserter 120, the protruding first side 943 engages afirst end of a compressed coil prior to engagement of the second end ofthe compressed coil by the second side 944 of the push plate 940. Aswill be appreciated, such engagement causes the compressed coil to splayas it is inserted into the top and bottom plies such that the first andsecond ends of the compressed coil are offset from the longitudinal axisof the coil. As will be appreciated further, the splaying of thecompressed coil during insertion assists in the eventual deployment ofthe coils, as is discussed below. The piece of fabric can then beadvanced along when the spring inserter 120 rotates, such thatadditional compressed springs can be ejected from the spring inserter120 and inserted between top and bottom plies of a piece of fabric atanother location along the fabric.

As shown in FIGS. 1, 7, and 10, some embodiments of the presentinvention can also comprise a fabric folding member 125 configured toreceive a piece of fabric and fold the fabric along its longitudinalaxis to produce a folded piece of fabric with top and bottom plies, afolded edge parallel to the longitudinal axis, and an open edge parallelto the longitudinal axis and opposite the folded edge. As shown in FIGS.1, 7, and 10, the fabric folding member 125 can comprise an angled sidesuch that the fabric propagates away from the folding member in adirection transverse to the direction in which the fabric is received tothe folding member 125.

As discussed above, the folded fabric can traverse a position proximatethe spring inserter 120 where the compressed springs are insertedproximate the open edge of the folded fabric between the top and bottomplies. After the compressed springs are inserted into the fabric, thefabric can traverse towards a first welder 130 that welds the top andbottom plies of the folded fabric together along the open edge. Afterthe open edge of the folded fabric is welded, that portion of the fabriccan traverse towards a second welder 135 that welds the top and bottomplies together along a line from the open edge to the folded edge(transverse to the longitudinal axis of the fabric) between each of thecompressed spring coils. In some embodiments, the second welder 135 isconfigured to weld two lines simultaneously on each side of thecompressed spring. The first and second welder 130 135 can join the topand bottom plies of the fabric together an accordance with manydifferent methods known in the art, including, but not limited to, hotweld fusing the top and bottom plies together, sewing the top and bottomplies together, applying an adhesive to join the top and bottom pliestogether, and the like. Additionally, the weld lines created by thefirst and second welders can be both linear and non-linear in accordancewith various embodiments of the present invention. For example, thefirst welder 130 could create a linear weld along the open edge and thesecond welder 135 could create a non-linear weld (or multiple non-linearwelds) between each of the compressed springs (e.g., the non-linear weldcould correspond to a non-linear exterior envelope of an expandedspring).

After weld(s) by the second welder 135, each compressed spring isenclosed in a pocket of the fabric. At this point, in accordance withsome embodiments of the present invention, the spring coils aremaintained in a compressed state while traversing through the first andsecond welders 130 135. The fabric containing the pocketed, compressedspring coils is traversed towards a spring expander (not shown). Forexample, in some embodiments, and as shown in FIG. 11b , opposingconveyor belts 1105 and 1110, which can have smooth, projectionlesssurfaces, can be located proximate the second welder 135. As shown inFIG. 11b , the top and bottom plies of the folded fabric can becompressed between the opposing conveyor belts 1105, 1110. Once thefabric exits the conveyor belts 1105, 1110, the compressed spring coilinside the fabric can begin to expand, and a rotating wheel 1115 canengage a top end of the compressed coil as the coil passes by therotating wheel 1115 and forces the top end to further splay andimmediately deploy to a decompressed state. The spring expander can beconfigured to allow the springs to expand within the pockets of thefabric. In some exemplary embodiments of the present invention, thespring expander can be configured to cause the compressed springs torotate about 90 degrees after engagement by the rotating wheel andexpand such that a longitudinal axis of the expanded spring coils istransverse to a longitudinal axis of the fabric (and parallel with alongitudinal axis of the corresponding pocket of the fabric). In someembodiments the spring expander can comprise a member that traverses anedge of the compressed spring to cause the compressed spring to rotate.In some embodiments of the present invention, the member can beU-shaped. In some embodiments of the present invention, the member canbe pivotably attached to a body of the spring expander, such thatpivoting of the member engages a portion of the compressed spring,causing the compressed spring to rotate and expand in the pocket. Insome embodiments, the member can actuate translationally with respect toa body of the spring expander, such that during translational movementof the member, the member engages a portion of the compressed spring,causing the compressed spring to rotate and expand in the pocket.

In addition to systems for producing a string of pocketed spring coils,various embodiments of the present invention are also directed towardsmethods of producing a string of pocketed spring coils. Methods of thepresent invention can include one or more steps carried out by varioussystem components described above.

Because various embodiments of the present invention allow multiplespring coils to be processed simultaneously (e.g., multiple spring coilsare simultaneously produced, transported, compressed, and inserted), thepresent invention allows a string of coils to be produced in a muchfaster and more efficient manner than conventional systems.

It is to be understood that the embodiments and claims disclosed hereinare not limited in their application to the details of construction andarrangement of the components set forth in the description andillustrated in the drawings. Rather, the description and the drawingsprovide examples of the embodiments envisioned. The embodiments andclaims disclosed herein are further capable of other embodiments and ofbeing practiced and carried out in various ways. Also, it is to beunderstood that the phraseology and terminology employed herein are forthe purposes of description and should not be regarded as limiting theclaims.

Accordingly, those skilled in the art will appreciate that theconception upon which the application and claims are based may bereadily utilized as a basis for the design of other structures, methods,and systems for carrying out the several purposes of the embodiments andclaims presented in this application. It is important, therefore, thatthe claims be regarded as including such equivalent constructions.

Furthermore, the purpose of the foregoing Abstract is to enable theUnited States Patent and Trademark Office and the public generally, andespecially including the practitioners in the art who are not familiarwith patent and legal terms or phraseology, to determine quickly from acursory inspection the nature and essence of the technical disclosure ofthe application. The Abstract is neither intended to define the claimsof the application, nor is it intended to be limiting to the scope ofthe claims in any way. Instead, it is intended that the invention isdefined by the claims appended hereto.

1.-21. (canceled)
 22. A spring expander system for causing a pluralityof compressed spring coils to deploy to a decompressed state, whereineach of the plurality of compressed spring coils are disposed within arespective pocket of a piece of fabric comprising a plurality of pocketsand each of the plurality of compressed spring coils deploys to adecompressed state within its respective pocket, the system comprising:a conveyor system comprising a first conveyor belt and an opposingsurface substantially parallel with a surface of the first conveyorbelt, the conveyor system configured to transport the plurality ofcompressed spring coils disposed in the respective pockets of the pieceof fabric between the first conveyor belt and the opposing surface, eachof the respective pockets having a first end and a second end with alongitudinal axis formed between the first and second ends, and each ofthe plurality of compressed spring coils disposed within the respectivepockets comprising a first end adjacent to and substantially parallel tothe surface of the first conveyor belt and a second end adjacent to andsubstantially parallel to the opposing surface; and a rotating wheelproximate an end of the first conveyor belt, the rotating wheelconfigured to engage a portion of the first ends of the plurality ofcompressed spring coils as each compressed spring coil exits theconveyor system and traverses past the rotating wheel, the engagementforcing the first ends of the compressed spring coils in a directiontowards the first ends of the respective pockets and causing thecompressed spring coils to rotate and decompress such that the firstends of the spring coils become proximate the first ends of therespective pockets and the second ends of the spring coils becomeproximate the second ends of the respective pockets such thatlongitudinal axes of the spring coils become parallel to thelongitudinal axes of the pockets.
 23. The spring expander system ofclaim 22, wherein the opposing surface comprises the surface of a secondconveyor belt.
 24. The spring expander system of claim 22, wherein theconveyor system further comprises a splaying member comprising a firstend, a second end, and an edge between the first end and second end, theedge configured to engage a portion of either the first ends or thesecond ends of the compressed spring coils when the compressed springcoils, disposed between the first conveyor belt and the opposingsurface, traverse past the splaying member, the engagement causing thecompressed spring coils to splay between the first conveyor belt and theopposing surface such that the longitudinal axes of the compressedspring coils form a non-normal angle to both the surface of the conveyorbelt and the opposing surface. 25.-50. (canceled)